Garment Manufacturing

Technology
RTW Apparel Production
Cut Order Planning
Total order of 1,80,000 shirts in four colour and four sizes with ratio as:
Red : White : Blue : Black :: 1 : 2 : 2 : 1
S : M : L : XL :: 1 : 2 : 2 : 1

Fabric consumption for each size:

S 1.2m
M 1.4m
L 1.6m
XL 1.7m

Size of spreading table 8m

Execute the cutting of fabric in least number of lays.

Process Flow
Sampling
Sampling
Raw Material Warehouse
Receive the fabric as per BOM
Fabric inspection (four point system)
Conduct fabric test (e.g. Shrinkage, colour fastness etc.)
Issue to the production department as per the requirement

Functions of the trims and accessories department

To receive incoming material.

To check material for attribute & variables.

To arrange the incoming material in allocated racks.

To issue trims as per BOM for sampling and production & other material
as per requirement.
To maintain a record of incoming & outgoing material.
RM Inspection
10% random inspection for sampling or lining or net fabric.
Inspection for production order fabric as per buyers requirement.
Perform GSM cutting.
Perform shrinkage test.
Check the fabric for the bowing or skewing.
Check fabric roll for the defects.
Allocate points to the defects.
4 point system

Size of Defect Penalty Points

Length of defects in fabric (either length or width)
Defects up to 3 inches 1
Defects > 3 inches < 6 inches 2
Defects > 6 inches < 9 inches 3
Defects > 9 inches 4
Holes and openings(largest dimension)
1 inch or less 2
Over 1 inch 4

In 4 point system fabric quality is evaluated by unit points/100 sq. yds.

Points / 100 sq. yd. = (Total points in roll * 36 * 100)/ (Fabric length in yards * Fabric width in
inches)

Normally fabric roll containing 40 points per 100 square yard are acceptable.
RM Storage
RM Movement
Cutting Department
Spreads

Markers
Planning
Production

Manual
Spreading
Machine

Manual
Cutting
Machine

Ticketing
Preparation
for sewing
Bundles
Market Segmentation
Cutting

Manual Machine

Portable cutting Stationary Position

Scissors
knives cutters markers
Band
Straight Notchers
knife knife
Die Drills and
Round cutting
knife
thread
Servo
markers
cutting
Plasma
cutting
Water jet
cutting
Laser
cutting